ROTEX A1 BO - professional.rotex-heating.com · The oil condensing boiler ROTEX A1 BO xxi may be...

For the operator

ROTEX A1 BOOil condensing boiler

Operating manual

Type Rated thermal output

ROTEX A1 BO 15bio 12–15 kW

ROTEX A1 BO 20i 12–20 kW



Serial number

Customer service

0645 BM

GBEdition 10/2007

Guarantee and conformity

2 BA ROTEX A1 BO - 10/2007

ROTEX provides a warranty for material and manufacturing defects according to this statement. Within the warranty period, ROTEX undertakes to have the unit repaired free of charge by a person assigned by the company.

ROTEX reserves the right to replace the unit.

The warranty is only valid if the unit is used properly and if it can be proved that it was installed correctly by a specialist company. As proof, we strongly recommend completing the enclosed installation and instruction forms and returning them to ROTEX.

Warranty period

The warranty period begins on the day of installation (billing date of the installation company), however at the latest 6 months after the date of manufacture (billing date). The warranty period is not extended if the unit is returned for repairs or if the unit is replaced.

Guarantee period for the burner and boiler electronics: 2 years.Guarantee period for the boiler body: 10 years.

Exclusion of warranty

Improper use, tampering with the unit and unqualified modifications immediately invalidate the warranty.

Dispatch and transport damage are excluded from the warranty.

The warranty explicitly excludes consequential costs, especially costs of installing and removing costs the unit.

There is no warranty for consumables (according to the manufacturer's definition), such as lights, switches, fuses.

Declaration of conformity

We, ROTEX Heating Systems GmbH, declare under our sole responsibility that the products

with the product ID No.: CE 0645 BM-105.2 together with one of the following control systems

comply, in their standard design, with the following European Directives:

2004/108/EC Electromagnetic Compatibility Directive

98/37/EC EC Machine Directive

2006/95/EC EC Low Voltage Directive

92/42/EEC EC Efficiency Directive

For the calorific value heating centres of the boiler series ROTEX A1 BO.

Product Order No. Product Order No.

ROTEX A1 BO 15bio 15 48 13 ROTEX A1 BO 27i 15 48 11

ROTEX A1 B0 20i 15 48 10 ROTEX A1 BO 35i 15 48 12

Product Order No.

ROTEX THETA 23R (N) 15 40 52

ROTEX THETA 23R (S) 15 40 53

ROTEX ALPHA 23R 15 40 54

Güglingen, 1.10.2007 Dr Eng. Franz GrammlingManaging Director

Contents

3BA ROTEX A1 BO Inline - 10/2007

1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1 Observing Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2 Warning signs and explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3 Avoid danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.4 Proper use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.5 Instructions for operating safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2 Product description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.1 Boiler design and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.2 Brief description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.3 Oil burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.4 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102.5 Hot water storage tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123.1 Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123.2 Instructions for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123.3 Initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143.4 Instruction and handover to the user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154.1 Controls on the boiler control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4.1.1 Control THETA 23R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154.1.2 Display and changing parameters (control THETA 23R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174.1.3 Control THETA 23R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.2 Heating operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194.2.1 Manual setting of the boiler temperature (control THETA 23R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194.2.2 Information on operating noises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4.3 Temporary shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214.4 Re-commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

4.4.1 Work to be done for re-commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224.4.2 Check list for re-commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4.5 Final shutdown and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

5 Service and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255.1 General overview of service and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255.2 Service and maintenance tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

5.2.1 Removing panelling (and cleaning it) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265.2.2 Checking the connections and pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265.2.3 Check water pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275.2.4 Checking the condensate treatment unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275.2.5 Checking and cleaning the combustion chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305.2.6 Check burner and oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

6 Faults and malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326.1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326.2 Burner malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326.3 Overview of possible malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336.4 Rectifying STL fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346.5 Emergency operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

7 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367.1 Dimensions and connection dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367.2 Basic data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387.3 Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

8 Glossary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

9 For the chimney sweep. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

1 x Safety

1 Safety1.1 Observing Instructions

These instructions are directed at the operator of the oil condensing boiler ROTEX A1 BO.

The installation, connection and initial start-up of the oil condensing boiler have been carried out by authorised and trained heating experts. The oil condensing boiler has been handed over to you properly by the installer. The handover is documented in the handover protocol.

All the activities required for operation, for returning to service after a temporary shut down as well as a few basic maintenance jobs are described in this manual. Activities for start-up, fault rectification and maintenance not described in these operating instructions may only be carried out by authorised and trained heating experts.

Please read these instructions carefully and in full before operating the oil condensing boiler.

Relevant documents– ROTEX A1 BO Installation and maintenance instructions for the heating expert.– The documentation of the ROTEX Control being used. It is included in the scope of delivery of the Control.

1.2 Warning signs and explanation of symbols

Meaning of the warningsWarnings in this manual are classified according into their severity and probability of occurrence.

Special warning signsSome types of danger are represented by special symbols:

Energy-saving tips and environmental protectionEnergy saving helps to reduce costs and to protect the environment. The notes for energy saving and environmental protection are marked with symbols in these instructions.

DANGER!

Draws attention to imminent danger.

Disregarding this warning can lead to serious injury or death.

WARNING!

Indicates a potentially dangerous situation.

Disregarding this warning can result in serious injury or death.

CAUTION:

Indicates a situation which may cause possible damage.

Disregarding this warning can lead to damage to property and the environment.

This symbol identifies user tips and particularly useful information, but not warnings or hazards.

Electrical current Danger of burning or scalding

Note for an energy saving procedure

General note for environmental protection

Notes for environmentally compatible disposal (recycling)

4 BA ROTEX A1 BO - 10/2007

1 x Safety

ValiditySome information in this manual has limited validity. The validity is highlighted by a symbol.

Order numberNotes related to Order numbers are identified by the cart symbol .

Handling instructions• Instructions on actions are shown as a list. Actions of which the sequential order must be maintained are numbered.

Results of actions are identified with an arrow.

1.3 Avoid danger

ROTEX oil condensing boilers are state-of-the-art and are built to meet all recognised technical requirements. However, improper use can lead to serious injuries or death, as well as causing material damage. To avoid danger, install and operate ROTEX oil condensing boilers only:– as stipulated and in perfect condition,– with an awareness of the safety and hazards involved.This assumes knowledge and use of the contents of this manual, the relevant accident prevention regulations and the recognised safety-related and occupational medical rules.

1.4 Proper use

The oil condensing boiler ROTEX A1 BO xxi can only be used for heating hot water heating systems. It must be installed, connected and operated only according to the information in this manual.

The oil condensing boiler ROTEX A1 BO xxi may be operated only in combination with a control unit approved by ROTEX (see conformity declaration on page 2 of this manual).

The oil condensing boiler ROTEX A1 BO may be operated only with the integrated circulation pump.

Any other use outside the above-mentioned use is considered as improper. Any resulting damages will be borne by the user/owner alone.

Intended use also includes compliance with the maintenance and service conditions. Spare parts must at least satisfy the technical requirements defined by the manufacturer. This is the case, for example, with original spare parts.

Valid only for ROTEX Control ALPHA 23R

Valid only for ROTEX Control THETA 23R

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5BA ROTEX A1 BO - 10/2007

1 x Safety

1.5 Instructions for operating safety

Training by the installer• The handover includes training in the operation and monitoring of the oil condensing boiler using the operating instructions

by the installer.• The handover should be documented by completing and signing the enclosed installation and training form with the engineer.

Fuel• Use only the approved heating oils as fuel (see chapter 7 "Technical data").

Installation room• Operate the oil condensing boiler only if sufficient combustible air supply is guaranteed. If operating the oil condensing boiler

independently of the ambient air with an air/flue system (LAS) with dimensions according to ROTEX-Standard, this is automatically guaranteed and there will be no further conditions required of the unit installation room.

• Make sure that there is a supply air opening to the open air, of at least 150 cm2 with ambient air dependent operation.• Do not operate the oil condensing boiler dependent on ambient air in rooms with aggressive vapours (e.g. hair spray,

perchloroethylene, carbon tetrachloride), strong dust formation (e.g. workshop) or high atmospheric humidity (e.g. laundry). • Always maintain the minimum distance away from walls and other objects (see chapter 3.2 and chapter 7).

Heating system• Work on the heating system (e.g. installation, connection and initial start-up) should only be carried out by authorised and

trained heating experts.• Switch off the mains supply before starting any work on the heating system and secure it against unintentional switch-on.• The heating system must comply with the safety requirements of EN 12828 as an open or closed heating system.• The safety valves must comply with DIN EN ISO 4126-1 and be type-tested. The safety valves must be installed in the safety

flow.• Always operate the oil condensing boiler with the sound insulation hoods closed.• The labels on the oil condensing boiler must not be removed or damaged.

Electrical installation• All the control and safety devices in the oil condensing boiler are connected ready for operation and are tested. Modifications

on the electrical installation are dangerous and prohibited. Any resulting damages will be borne by the user/owner alone.• Electrical installations may only be carried out by qualified electrical technicians under observance of the relevant electrical

guidelines and the regulations of the electric utilities company.

Air/flue system (LAS)• The air/flue gas system (LAS) must not be modified arbitrarily by the operator. Modification to the combustion air supply and

the flue gas ducting must only be carried out by authorised and trained technicians in consultation with the regional chimney sweep.

Disposal• Through the environmentally-friendly design of the oil condensing boiler, ROTEX has complied with the requirements for

environmentally-friendly disposal.• Proper disposal in compliance with the respective national regulations of the country of use is the responsibility of the

user/owner.

Documentation• The technical documentation included in the scope of supply is a constituent part of the equipment. It must be stored in such

a way that it can be consulted at any time by the operator or the technicians.

6 BA ROTEX A1 BO - 10/2007

2 x Product description

2 Product description2.1 Boiler design and components

A1 BO 15bio / A1 BO 20i A1 BO 27i / A1 BO 35i A1 Schematic drawing

Fig. 2-1 Boiler components – View from the front Fig. 2-2 Diagram A1-boiler

A1 BO 15bio / A1 BO 20i A1 BO 27i / A1 BO 35i

Fig. 2-3 Boiler components – View from the back

1 Sound insulation hood 2 Boiler control panel3 Boiler panelling4 Burner 5 Controller6 Boiler main body with heat and sound

insulation7 Type plate with manufacture number8 Circulation pump9 3-way diverter valve

10 Heater return flow (cold)11 Heating flow (hot)12 Manometer 13 Filling and draining cock14 Safety valve15 Flue gas/supply air connection16 Condensate treatment unit17 Condensate drain18 Air supply hose19 Flame tube

20 Combustion chamber insert21 Flue gas temperature sensor 22 Circuit board (electrical connections)23 Stickers for identification of the usable oil quality24 Document pouch25 Ball stopcock26 Flow temperature sensor 27 Return flow temperature sensor

Safety devices

2 4

18

26

149

8

21

15

16172019

25



2.2 Brief description

The ROTEX oil condensing boiler in the series A1 BO combined with the ROTEX controller to be ordered separately is a premounted oil fired boiler unit.

Operating modeThe ROTEX oil condensing boiler A1 BO is designed in such a way that it can be operated independent of ambient air. The burner suctions the combustion air directly in through an installation shaft or a double-walled flue gas pipe. This operating mode has several advantages:– The heating room does not need any ventilation opening into the open air and therefore does not cool down.– Lower energy consumption.– Additional energy recovery in the flue gas pipe through preheating the combustion air.– Contamination from the environment of the burner are not suctioned in. The heating room can thus be used as a workspace,

laundry room etc. at the same time.– Possible to set up in loft areas or attic.– Possible to set up in garages.The collecting condensate is neutralised in the integrated ROTEX condensate treatment unit and then conducted into the drainage system through a plastic tube.

Safety managementThe entire safety management of the oil condensing boiler is managed through an electronic control panel. If there is water shortage, oil shortage or undefined operating conditions, there is a safety shutdown. A corresponding fault signal provides an engineer with all the necessary information for troubleshooting.

Electronic controlAn electronic digital controller combined with the "intelligent" automatic firing unit of the burner controls all heating and hot water functions automatically for the direct heating circuit, an optionally available mixed heating circuit as well as a storage tank charging circuit.

All settings, displays and functions are carried out by the ROTEX-THETA control. The ROTEX THETA 23R control or the ROTEX ALPHA 23R control can be used according to the equipment version. The display and keyboard make it easy to use.

A digital room station (THETA RS, 15 70 18) or a room temperature controller set (THETA RFF, 15 40 70) are available as option for greater convenience.

The room temperature control (ALPHA RTR-E, 17 51 26) is available as option for greater convenience.

Condensing technologyCondensing technology makes optimum use of the energy contained in the heating oil. The flue gas is cooled down in the boiler and in the flue system - when operated independently of ambient air – such that the temperature is below the dew point. Part of the water vapour created on combustion of the oil thereby condenses. The condensation heat is fed to the heating, in contrast to low-temperature boilers, thus making it possible to achieve over 100 % efficiency.

FuelThe ROTEX oil condensing boiler A1 BO can be operated with standard or low sulphur heating oil (sulphur content < 50 ppm). It is prepared for combustion of heating oil with biogenic content. As things currently stand, admixing bio-heating oil up to 10 % (B10) is permitted without an additional conversion being required.

The ROTEX oil condensing boiler A1 BO 15bio is equipped with components that allow an admixture of bio-heating oil up to 20 % (B20).

Condensate treatmentThe condensate generated during the combustion in an oil condensing boiler has a pH value of 1.8 to 3.7. It must be neutralised before it enters the drainage system.

The ROTEX condensate treatment unit fulfils the following functions:– Removes floating particles in the settling basin,– Neutralises the condensate in the shell limestone.

ROTEX recommends using EL low sulphur heating oil in order to achieve highest efficiency and to keep maintenance expenditure low.

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8 BA ROTEX A1 BO - 10/2007


2.3 Oil burner

1 Automatic oil firing unit2 Oil pump3 Suction line connection4 Return line connection5 Adjusting screw for recirculation opening6 Scale of recirculation opening7 Scale of air throttle8 Adjusting screw for air throttle9 Reset button for oil burner10 Holder for service position11 Blue Flame Meter12 Service Allen key13 Burner flange with seal14 Flame tube15 Flame monitor16 Connection for remote unlocking17 Connector socket, 7 pin18 Fan rigid in compression19 Air supply connector20 Electric motor21 Service screw22 Recirculation tube23 Nozzle connection cover

Fig. 2-4 Oil burner top view (rear view)

Fig. 2-5 Oil burner – Side view from left

Fig. 2-6 Oil burner – Side view from right

11

10

12

8

7

6 5 21 15 9

1

20

2

4

3

17

19

18

16

10

12

17

1 16 21 13 22 14

23

4

23

11

10

18

8

7 21 13 22 14

19



Burner setting and limiting output The oil burner is set to a specific output in the factory (see tab. 7-3).To optimise the burner output, the heating expert can:– change the pump pressure,– adapt the air volume,– regulate the combustion quality,– if big adjustment has been made to output: change oil nozzle and air nozzle.

Controlling the flow temperatureThe control system installed in each case continuously determines the required flow temperature and, if required, sends a burner demand to the automatic firing unit DKO 974 of the oil burner.

Automatic firing unit DKO 974The automatic oil firing unit DKO 974 controlled by a microprocessor and monitors the firing programme. It features the following properties:– Stable programme times, independent of the fluctuations in the mains voltage or ambient temperature.– Operating safety, even in the event of power failures. The automatic firing unit switches off in the event of a power failure

without a fault signal and on again once the normal voltage has been resumed.An LED in the reset button of the automatic firing unit indicates the burner control processes. In normal operating mode the LED sends a short flashing signal followed by an extended pause. In the event of malfunction, a flashing code provides information on the cause of the fault (see chapter 6 "Faults and malfunctions").

2.4 Connections

Integrated connection groupThe integrated connection group is a compact unit for connecting a heating circuit and a hot water tank to the oil condensing boiler ROTEX A1 BO.

The integrated circulation pump allows the required water to flow through the oil condensing boiler and the active circuit (hot water storage tank or heating circuit). The 3-way diverter valve switches between the heating circuit and the hot water storage tank as required by the boiler control.

Temperature sensorThe oil condensing boiler has a weather-driven control for the flow temperature. This function requires an external temperature sensor. A 3 m flexible cable is already connected inside the unit and placed in the control panel on the connecting circuit board.

The temperatures captured by the unit's internal temperature sensors (flow and return flow temperature sensor, flue gas temperature sensor) are used for the output control of the burner and for fault detection. The temperature sensors are already factory-connected and can be plugged directly to the respective sensor, if they need to be swapped.

If a hot water storage tank is used, the connected storage tank temperature sensor must be mounted at the suitable position in the hot water storage tank (observe installation instructions for the hot water storage tank). The mixer circuit flow sensor (TMKF, 15 60 62) is required to control the mixer circuit .

Information on the dimensions and connection dimensions can be taken from chapter 7 "Technical data".

The electronic control unit detects the existing sensor configuration automatically when switching on the oil condensing boiler for the first time.

You will find more instructions and an exact description in the documentation "ROTEX Control". It is included in the scope of supply of the particular electronic control to be ordered separately.

10 BA ROTEX A1 BO - 10/2007


Mixer circuit (optional)A mixer circuit can be connected directly to the oil condensing boiler which is controlled through the electronic boiler control. ROTEX offers the following:– The ready-to-connect mixer group AMK1 ( 15 60 44), which contains a circulation pump integrated in the heat insulated

housing, a motor mixer and stop valves with temperature displays.– The mixer circuit contact sensor TMKF ( 15 60 62).

By cascading from the heat circuit expansion modules THETA HEM1 ( 15 60 61), the system can be expanded by up to 5 mixer circuits and/or storage tank charging circuits. The required temperature sensors need to be ordered separately (mixer circuit contact sensor TMKF ( 15 60 62), storage tank temperature sensor TSF ( 15 60 63)).

Room controller (optional) You can connect a separate room temperature controller THETA RFF ( 15 40 70) for each heating circuit to remotely

set operating modes and room temperatures from another room.

You can connect a separate room temperature controller ALPHA RTR-E ( 17 51 26) for each heating circuit to remotely set operating modes and room temperature from another room.

Room station (optional)All temperature values and operating modes of the control unit THETA 23R (central unit) can be displayed and changed

through the room station THETA RS ( 15 70 18) . Apart from the chimney sweep and manual operation function, all controls (display, buttons, rotary switch and functions (e.g. timer programmes) are identical to those on the central unit.

The room station THETA RS can be installed in a suitable place in the building and can be used to remotely operate the boiler control unit.

2.5 Hot water storage tank

There are 5 types of hot water storage tank available for the oil condensing boiler A1 BO. The ROTEX Solaris System for hot water preparation can also be incorporated.

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For further information on hot water storage tanks, please consult the documentation for Sanicube INOX, Sanicube PEX and Solaris.

For further information on incorporating a hydraulic system, please contact your ROTEX dealer.

11BA ROTEX A1 BO - 10/2007

3 x Start-up

3 Start-up3.1 Safety

The following notes apply specially to transport, installation and initial start-up:– Only lift the gas condensing boiler using the carrying straps provided for this purpose. Lifting or moving the oil condensing

boiler by the panels can damage the unit. – The installation site must be solid, flat and horizontal. Install a pedestal if necessary.– Requirements of the room for installation to be taken into account (see chapter 1.5).– The Firing Ordinance of the respective state and EN 14478 are valid for the model and dimensioning of the flue system.

The properties of the flue gas system must be clearly evident on the heating system (nameplate in the installation room).– The certified company carrying out the work must come to an agreement with the district chimney sweep before beginning

the work. We recommend maintaining a record of the involvement of the regional chimney sweep on file using a pre-printed form.

– The properties of the flue gas system must be clearly evident on the system (nameplate in the installation room).– The electrical connection should only be made by electrical engineers in compliance with valid standards and guidelines as

well as the specifications of the energy supply company.

3.2 Instructions for installation

Scope of delivery– Oil condensing boiler (preassembled).– Accessories package (diverter valve, T-piece, ball cocks, external temperature sensor, spare microfilters inserts, seals, double

box nuts).– The document folder with the installation and maintenance instructions, operating instructions and installation and training

form.

Status at the time of deliveryThe following outputs are factory-set:

Tab. 3-1 Factory setting and output range

WARNING!

An oil condensing boiler not started up properly can be a health and safety risk endangering human life and adversely affect its operation.• Start-up of the oil condensing boiler may only be carried out by authorised and trained heating engineers.

Incorrect start-up makes the manufacturer's guarantee for the unit void.

If there are any questions, please contact your heating system installer or our technical customer service.

The oil condensing boiler will not function without a central control unit. The control unit must be ordered separately in the desired model (operation allowed only with ROTEX controls).

Type Pre-set output Output range

A1 BO 15bio 14 kW 12–15 kW

A1 BO 20i 18 kW 12–20 kW

A1 BO 27i 25 kW 20–27 kW

A1 BO 35i 30 kW 25–35 kW

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3 x Start-up

Different set-ups– The oil condensing boilers in the series A1 BO are basically designed for operation independent of ambient air. They are

fitted with a concentric flue gas/air supply pipe DN 80/125. ROTEX recommends operating the oil condensing boiler independently of ambient air. If possible, choose this set-up!

– When operating with partly room air independent or room air dependent modes, the installation room must have a ventilation opening of at least 150 cm2 to the open air.

– When operating partially independent of ambient air and with ambient air dependent operation, the installation room must be free from aggressive vapours (e.g. hair spray, perchloroethylene, carbon tetrachloride), heavy dust formation and high atmospheric humidity (e.g. utility room).

Set-up in garagesThe oil condensing boilers of series A1 BO are basically suitable for being set-up and operated in garages. Requirements:– Operation independent of ambient air,– A durable instruction manual placed in a very visible place near the boiler,– The construction must include a protective device against mechanical damage (vehicle!) for the entire system (e.g. bracket

or deflector).

Set-up in the atticIf the A1 condensing boiler is installed in the attic and the oil is stored in the rooms below it, the oil pump of the burner is generally not adequate. Since the vacuum on the suction side exceeds the value of 0.4 bar, the oil must be supplied to the burner through a separate pump.

Please note the following for set-up in the attic:– Install the boiler in a leakproof tray and secure through a float switch (connection through additional plug strip ZSÖ,

15 40 67).– Use only a metallic filter cup (never Plexiglas).– To prevent malfunctions when starting or in operation of the burner the minimum height of the flue pipe must be 2 m.

Installation heightThe bottom edge of the condensate drain connection on the unit must be higher than the outlet height of the condensate drainage hose, otherwise condensation can accumulate in the drain.When installing with an adjacent storage tank the boiler should be mounted on a plinth at least 80 mm high.

Water qualityIf the oil condensing boiler is connected to a heating system with steel pipelines, radiators or non-diffusion-proof floor heating pipes, slurry and chips could enter the boiler and cause blockages, overheating or corrosion. For this reason ROTEX recommends fitting a dirt filter in the heating return flow.

If filling and additional water has a high degree of hardness (Sum of alkaline earths >3 mol/m3), measures need to be taken to stabilise or soften hardness.

Heating oil storage in the installation room

As a general rule, construction specifications allow up to 5000 litres of heating oil to be stored in the installation room (according to the Firing Ordinance of the state) if the building is in Building Category 1 and the installation room is not a living room.

ROTEX urgently recommends using a suction aggregate, because if you use a pressure aggregate, hydraulic oil could escape if there is a fault.

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3 x Start-up

Surface temperature– When operating independently of the ambient air with nominal output, the design does not allow temperatures > 70 °C on

any component outside the unit panels. Therefore, no minimum distance is required to components made with flammable materials.

– A minimum distance of 20 mm between the flue gas pipe and flammable components should be maintained with partial ambient air-independent and ambient-dependent operation.

– Do not store or use highly combustible and flammable materials in the immediate vicinity of the oil condensing boiler.

3.3 Initial start-up

After the oil condensing boiler has been installed and fully connected, it can be started up by trained staff.

3.4 Instruction and handover to the user

The oil condensing burner will be handed over to you after it has been started up by the technicians. During handover, the installer will train you on how to operate and use the oil condensing boiler.

The training will consist of at least the following:– Explanation of the safe and intended use of the oil condensing boiler and the legal responsibilities which you have as the

operator of the oil heating system.– Explanation of the operating elements and the setting facilities that you can use.– Explanation of the operating modes and instructions for economical and energy-saving operation.– Explanation of the required cleaning and maintenance work which you can carry out.– Procedure in the event of a fault.

A flue gas temperature sensor integrated in the control unit of the oil condensing boiler triggers a safety shutdown if the flue gas temperature is too high.No additional insulation is needed on site in Germany.

WARNING!

An oil condensing boiler not started up properly can be a health and safety risk endangering human life and adversely affect its operation.• Start-up of the oil condensing boiler may only be carried out by authorised and trained heating engineers.

The requirements and tests before start-up, the start-up activities and the required tests are described in detail in the installation and maintenance instructions for the expert operation mode.

The scope of supply includes an installation and training form. Correct handover should be recorded in the files by completing this form jointly with the installer.

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4 x Operation

4 Operation4.1 Controls on the boiler control panel

4.1.1 Control THETA 23R

Mains switchSwitches the oil condensing boiler on and off. When the heating system is on, the mains switch is illuminated green.

Burner malfunction indicatorDuring normal operation, the burner malfunction indicator is off. When it lights up, it indicates a burner malfunction.For troubleshooting instructions, see chapter 6.2.

STL indicatorThe STL indicator is off during normal operation. When it lights up, it indicates a safety temperature shutoff due to a serious malfunction in the heating system (e.g. pump defect, clogging or air in the system). For troubleshooting instructions, see chapter 6.4.

Pressure gauge– Black pointer: Indication of the current water pressure in the heating system.– Green range: Permitted water pressure range.– Red pointer: Indication of the permitted minimum pressure.The black pointer must be in the green range. If it is to the left of the red pointer, the water pressure must be increased by topping up the system (see section 4.4.1).

The ROTEX oil condensing boiler A1 BO can be operated with the THETA 23R controller or with the ALPHA 23R controller. The electronic digital controls are to be used for controlling 2 heating circuits (direct heating circuit, mixer circuit) and a storage tank charging circuit.

You will find an exact description in the respective documentation on the ROTEX Control.

Fig. 4-1 Controls on the boiler control panel

1 Mains switch2 Burner malfunction indicator3 STL indicator4 Manometer5 Controller: Central unit THETA 23R6 Rotary switch for selecting and setting functions

and parameters7 Selecting the target room temperature during day8 Selection of the reduced target room temperature9 Selection of the target temperature for the hot water storage

tank

10 Selecting the operating mode11 Setting automatic timer programme12 System information13 Manual button for emission measurement,

manual operation, reset function14 Display15 Compartment for quick reference instruction manual16 Fixing screws for the control unit17 Safety temperature limiter (STL)

Malfunctions are generally indicated by a fault code on the display.

For troubleshooting instructions refer to chapter 6 "Faults and malfunctions".

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4 x Operation

Safety temperature limiter (STL)The safety temperature limiter shuts off the burner if the boiler temperature exceeds the permissible limit and locks it against automatic restart. For manual unlocking, see chapter 6.4.

Rotary switchThe rotary switch can be used to select operating settings, changing and storing target values.

Target room temperature during daySelection and setting of the target temperature in normal operation. Set according to individual temperature sensitivity.

Reduced target room temperatureSelect and set the target temperature in economy operation (night reduction). Set according to individual temperature sensitivity.

Target temperature hot water storage tankSelect and set the target hot water storage tank temperature Set according to specific hot water requirements.

Selecting the operating modeSet the operating mode by tapping the operating mode selector button. The operating mode that is currently active flashes on the display. Select and activate another operating mode with the rotary switch. A marking on the display above the respective symbol shows the mode currently selected.

* This function is not available if a room temperature controller THETA RFF is connected or if the operating mode of the control has been set at different settings for the individual heating circuits.

Setting automatic timer programmeSelect one of the 3 pre-installed timer programmes P1, P2 or P3. You can find further instructions and a more exact description in the documentation for "ROTEX controller THETA 23R". It is included in the scope of supply of the particular electronic control to be ordered separately.

System informationQuerying all system temperatures and operating statuses of the system components.• Tap the system information button.• Query the desired information successively by using the rotary switch.

• Rotate to the right (+): Increased regulation• Rotate to the left (–): Reduced regulation

• Tap: Save the selected value

• Press and hold (3 sec): Enter the programming level (select level)

It is possible to trigger an unscheduled storage tank charge by keeping the button pressed for a long time (during an economy phase).

HOLIDAY Frost -protected shutdown of heating and hot water (e.g. during holidays).

ABSENT Brief break in the heating mode during absence.

PARTY Extended heating mode over and above the heating period preset in the AUTOMATIC MODE.

AUTOMATIC Automatic heating and economy mode according to timer programme.

SUMMER Hot water mode according to timer programme, heating switched off with frost-protection.

HEATING Continuous heating mode without time restriction.

REDUCED Continuous reduced heating mode without time restriction.

STANDBY Frost-protected shutdown of heating and hot water.

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4 x Operation

Emission measurement, manual operation, reset functionYou can request 3 functions by using the Manual button.a) Functions for emission measurement for the chimney sweep: Tap Manual button.

– First tap: The burner is turned on for 20 min. and is regulated at the stipulated maximum temperature. The 3-way diverter valve is at "Storage charge" until the maximum adjustable storage temperature is achieved. Finally, switch to the heating mode.

– Tap a second time: early cancellation.b) Manual operation: Press the Manual button for 5 sec. The oil condensing boiler is controlled according to the set target value

(heat generator temperature). The storage tank charges until the maximum adjustable storage tank temperature is reached. It then switches over to heating.

c) Reset: If the display shows "RESET", tap the Manual button. If the malfunction occurs repeatedly, the cause must be rectified. Please consult a heating expert in this case.

DisplayAll system temperatures and operating statuses of the system components can be shown on the display. In the event of a malfunction, the corresponding fault signal is issued.

Standard display in normal operating mode: Current day of the week, current date, current time, heat generator temperature and active operating mode (marking bar).

4.1.2 Display and changing parameters (control THETA 23R)

Basic Display

Changing parametersAll parameters for operating the heating system can be displayed and changed in the boiler control panel. You do not have access to the setting areas. They are protected by an access code and can only be called up by an authorised heating expert.

The parameters can be changed as follows:• Push the selection button of the parameter to be changed (e.g. for setting the automatic timer programme).• Select the parameter by turning the rotary button to the left or to the right until the desired value is shown in the display.• Accept the selection by pushing the rotary button.

In these instructions you get an overview of the display on the boiler control panel and of the basic procedure for changing the parameters on the THETA 23R controller.

You will find an exact description in the respective documentation for the controller.

The display shows the current operating parameters in normal operating mode:– Day of the week, date, time, heat generator temperature.

The marker bar indicates the active operating mode(example shows Automatic, Timer Programme II).

Special characters:– Ice crystal: System frost protection active.– Parasol: Summer switch-off active.

Fig. 4-2 Basic display THETA 23R

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4 x Operation

4.1.3 Control THETA 23R

"Default settings" rotary switch

Rotary switch "Selecting the operating mode"

Only the control and display elements of the ROTEX central control unit ALPHA 23R are described below. For the controls of the complete boiler control panel, see section 4.1.1.

Fig. 4-3 Controls on the boiler control panel with integrated control ALPHA 23R

1 Mains switch2 Burner malfunction indicator3 STL indicator4 Manometer5 Central unit ALPHA 23R6 Rotary switch for the default settings10 Rotary switch for selecting the operating mode

14 Display15 Compartment for quick reference instruction manual16 Locking the control in place17 Safety temperature limiter (STL)27 Button28 Button29 Button

NORMAL OPERATING MODE

Controller works according to the operating mode set with the "Selection of operating mode" rotary switch.

TARGET HOT WATER TEMPERATURE

Display and modify target hot water temperature.

TARGET ROOM TEMPERATURE

Display and change target room temperature.

STATUS PLANT Read information on the plant status.

WEEKDAY Display and change weekday.

CLOCK TIME Display and change time.

PARAMETER Select and change parameters.

STANDBY Frost-protected shutdown of heating and hot water.

REDUCED Continuous reduced heating mode without time restriction.

HEATING Continuous heating mode without time restriction.

SUMMER Hot water mode according to timer programme, heating switched off with frost-protection.

AUTOMATIC IAutomatic heating and lowering mode according to switching timer programme "Out at work"(can be set separately).

AUTOMATIC II Automatic heating and economy mode according to timer programme "Family".

AUTOMATIC III Automatic heating and economy mode according to timer programme "Solar".

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4 x Operation

Changing values, Navigation– Changing values.– In the function menus "Parameter", "Status Plant" and "Automatic I", the buttons help with navigation.– Press briefly the and buttons simultaneously to confirm and/or save the selected setting.

RESET– Reset the fault signal in case of burner malfunction.– Abort the control measurement.– Reset entries in a function menu.– Return to higher-level selection point within the function menu.– Operator acknowledging fault signals and returns to default display.

Special functionsSimultaneously pressing the and buttons for longer than 2 seconds activates Emission measurement .

Pushing the buttons and simultaneously activates the Switching time programming for the switching time programme „Automatic I" (for precise information refer to the instruction manual of the ROTEX control unit ALPHA 23R).

DisplayAll system temperatures and operating statuses of the system components can be shown on the display. If there is a malfunction, a fault code is displayed.

Standard display in normal operating mode: Flow temperature.

4.2 Heating operation

In normal operation, the boiler temperature regulator always operates in automatic or continuous operation mode. The boiler temperature is controlled depending on the weather.

4.2.1 Manual setting of the boiler temperature (control THETA 23R)

When using the THETA 23R controller, the ROTEX A1 BO can be controlled manually to manually heat up the heating system or to temporarily manually adjust the boiler temperature.

• Switch on the mains switch. Wait for the start phase.• Set the operating temperature for manual operation.

Press Manual button for approx. 5 s

Target temperature

Change Desired target value (flashing)

Currentactual value

Return to the original operating mode, default display, set target value is saved

Fig. 4-4 Manual mode for control THETA 23R (set heat generator temperature)

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4 x Operation

Pump setting for energy-saving operation (A1 BO 20i)The ROTEX oil condensing boiler A1 BO 20i is equipped with a three stage circulation pump which normally has enough output to supply the complete heating system. Additional pumps are only required if mixed heating circuits are installed.

The other variants of the A1 BO oil condensing boiler have a controlled heating pump which the heating expert sets up optimally during start-up. Manual adjustment of the pump output level is also possible on this pump, but is not required.

The pump fitted in the oil condensing boiler ROTEX A1 BO20i consumes approx. 75–80 W at output level 3, approx. 55–60 W at output level 2.

Determination of the required pump level

• Determine the flow rate associated with a specific heating output in the heating output diagram (fig. 4-5) depending upon the design spread.

Depending upon the heat demand and the temperatures the heating system is designed for, the circulation pump can also be operated at a reduced speed without having a detrimental effect on the heat provided. This allows you to save on electricity to drive the pump.

The operator can only use output levels 2 and 3 for pump adjustment. The lowest output level is blocked for safety reasons.

Q Heating outputmH Flow heating network

Fig. 4-5 Heating output diagram

The design spread describes the temperature difference between the flow and return flow of the heating system under design conditions (generally –12 °C outside air temperature).

ΔpR Remaining pumping heightmH Flow heating network

Fig. 4-6 Remaining pump height of the circulation pump fitted in the A1 BO 20i oil condensing boiler

S= 20 K

S= 15 K

S= 10 K

0

5

10

15

20

25

30

35

0 500 1000 1500 2000 2500 3000

13

700 m / L/hH

Q/

kW

0

100

200

300

400

500

600

0 200 400 600 800 1000 1200 1400 1600 1800 2000

II

III240

700m / L/hH

p/

mbar

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4 x Operation

• Find the hydraulic resistance of the heating network in the piping network calculation for your heating system.• Using fig. 4-6, determine the required heating level of your heating pump.

• Set the pump to the required output level (fig. 4-7).

Example for determination of the pump output level– Heat requirement: 13 kW, design temperatures: 75/60 °C, Spread: 15 K, required flow rate: 700 l/m, hydraulic resistance in

heating network: 240 mbar.

In the design case, pump level 2 will be adequate.

4.2.2 Information on operating noises

In some cases, the resonance in the flue system can amplify the noise at the mouth of the flue gas pipe. The noise level can be effectively reduced by using a noise damper ( 15 45 78).

Air suction noises are generated during ambient air-dependent operation. The noise level can be effectively reduced by using a noise damper ( 15 45 77).

4.3 Temporary shutdown

If no heating and no hot water supply is needed over a long period, the oil condensing boiler can be temporarily shut down. ROTEX, however, recommends putting the system on Standby mode (see Documentation "ROTEX Control"). The heating system is then protected from frost. The pumps and valve protection functions are active.If it is not possible to guarantee the oil and power supply when there is danger of frost,– the oil condensing boiler must be drained,– the condensate treatment unit must be drained (see chapter 5.2).– suitable antifreeze measures must be taken for the connected heating system and hot water storage tank (e.g. draining).

In practice, the hydraulic resistance in the heating network is often not known. By observing the flow and return flow temperatures on the heat generator, you can determine whether the pump would still provide adequate output at a lower speed level.

The difference between the flow and return flow temperature must not be greater than the design spread and each room must still get warm enough.

1 Heating pump2 Setting lever of the pump output level

Fig. 4-7 Setting the pump output level

2

1

CAUTION!

A heating system which is shut down can freeze in the event of frost and may suffer damage.• Drain the heating system that is shut down if there is danger of frost.• If the heating system is not drained and there is the risk of frost, the oil and power supplies must be secured

and the main switch must remain switched on.

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4 x Operation

Draining the heating system• Switch off the main switch and secure against restarting.• If a hot water storage tank is fitted: Drain the storage tank in accordance with the manufacturer's instructions.• Close the stop valve on the oil filter.• Bleed all the water in the entire system at the filling and draining sockets (KFE cock).

4.4 Re-commissioning

If the ROTEX Oil condensing boiler A1 BO has been out of service for an extended period, certain preparatory tasks and tests need to be carried out for re-commissioning.

4.4.1 Work to be done for re-commissioning

Fill condensate drain with water.In order to prevent flue gas from escaping into the installation room, the condensate treatment unit must be connected correctly.• Unscrew the inspection

cover of the connection piece in the flue gas pipe.• Fill the condensate treatment unit with water using a tube held in the flue gas pipe.• Screw the inspection cover back in position and check the condensate drain route for leaks.

Filling the heating system• Connect the filling hose with return flow inhibitor (½") at the filling and draining fittings (KFE cock, fig. 7-3, pos. 3) and

secure against sliding by using a hose clamp.• Open the KFE cock and watch the pressure gauge (fig. 2-1, pos. 12).• Fill the system with water until the marking of the system overpressure is roughly in the centre of the green range of the

pressure gauge display.• Close the filling & draining cock.• Bleed the entire heating network (open the regulating valves in the heating system).• Check the water pressure on the pressure gauge again and top up with water if necessary.• Close the KFE cock, remove the filling hose and return flow inhibitor from the filling and draining fittings.

Checks before start-up• Check all connections for leakage.• All the points in the enclosed checklist to be checked (see section 4.4.2) and record the test results.• Only if all points on the checklist have been answered with a "yes" may the oil condensing boiler be started up again.

Function testing after start-up

After completing the start-up activities the function of the heating must be checked.

• Open the regulating valves in the heating system.• Manually adjust the target temperature (see section 4.2.1).

• Set the control for a control measurement (see chapter 9).

The temperature of the boiler rises slowly.

In case of systems with a hot water storage tank: the temperature of the storage tank rises slowly.The oil condensing boiler charges the storage tank until the maximum adjustable storage tank temperature is achieved. It then switches over to heating operation.

• Check all the points on the enclosed checklist (see section 4.4.2) and record the test results.• Set the desired operating mode (see section 4.1.1 or section 4.1.3).• Set the regulating valves in the heating system to normal operating mode.

If irregularities arise during the function check after start-up or during the first few days in operation, please contact your heating expert.

In order to ensure safe, energy-saving and environmentally-friendly operation of the oil condensing boiler, ROTEX recommends having the settings checked after re-commissioning by a heating expert.

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4 x Operation

4.4.2 Check list for re-commissioning

Checklist before start-up

1. Is the boiler properly assembled in an authorised way and without visible damage? Yes

2. When using a pressure assembly: Is the installation site additionally secured (leakproof tray, filter cup of metal)? Yes

3. Is the combustion air supply secured? Yes

4. Is sufficient venting assured for the heating room in ambient air - dependent operation? Yes

5. Does the mains connection conform to the specifications? Yes

6. Is the mains voltage 230 Volt, 50 Hz? Yes

7. Is the LAS flue gas pipe connected correctly and leakproof? Yes

8. Is the condensate treatment unit correctly connected, filled with water and leakproof? Yes

9. On restoration: Has the heat distribution network been cleaned? Is a dirt filter built into the heating return flow? Yes

10. Is a membrane expansion tank mounted according to specifications and in the requisite size? Yes

11. Is the safety valve connected to a free outlet? Yes

12. Has the quality of the filling water been checked and has the required water preparation been carried out? Yes

13. Is the system water pressure within the green range? Yes

14. Are boiler and heating system vented? Yes

15. In case of systems with a hot water storage tank: Is the storage container filled? Yes

16. Are all sensors connected and correctly positioned? Yes

17. Is the 3-way diverter valve correctly mounted and inserted on the flow connection? Yes

18. Are the mixer group and the mixer circuit sensor (optional) correctly connected to the circuit board? Yes

19. Is the room temperature controller or room station (optional) correctly connected to the circuit board? Yes

20. Is the oil connection installed according to regulations, professionally and correctly? Yes

21. Is the oil tank topped up sufficiently and are the oil valves open? Yes

Only if all questions can be answered with a "yes" may the system be started up again!

Checklist after start-up

A. Does the boiler temperature increase slowly after opening the regulating valves? Yes

B. In case of systems with a hot water storage tank: Does the temperature of the storage tank increase slowly in parallel with the boiler temperature?

Yes

C. In case of systems with a hot water storage tank: Does the oil condensing boiler switch over to heating operation after reaching the maximum adjustable storage tank temperature?

Yes

D. In case of systems with a hot water storage tank: Does the temperature of the radiators increase slowly after charging the storage tank has finished?

Yes

E. Are all the heating pipes free from leaks? Yes

Only if all questions can be answered by "yes" may the system be started up again.

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4 x Operation

4.5 Final shutdown and disposal

For final shutdown, the oil condensing boiler must be• taken out of service,• disconnected from all electrical, oil and water connections,• disposed off in a professional manner.

Recommendations for disposalThe ROTEX oil condensing boilers are designed to be environmentally friendly. During the disposal process, the only waste accrued is that which can be used for material or thermal recycling. The materials used can be separated into different types.

Through the environmentally-friendly design of the oil condensing boiler, ROTEX has complied with the requirements for environmentally-friendly disposal. Proper disposal in compliance with the respective national regulations of the country of use is the responsibility of the user/owner.

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5 x Service and maintenance

5 Service and maintenance5.1 General overview of service and maintenance

Regular service and maintenance of the heating system keeps energy consumption down, guarantees a long working life and fault-free operation of the heating system.

Tests during the annual service:– General condition of the heating system, visual inspection of connections and pipes.– Flue gas temperature and flue gas temperature sensor.– Functioning of the condensate treatment unit (determination of pH value).– Burner operation and burner settings.

Maintenance work to be carried out annually:– Cleaning the burner components, the combustion chamber and the heating surfaces.– Cleaning the boiler panelling and the sound insulation hood.– Cleaning and regeneration of the Condensate treatment unit.– Replacement of the consumables (if required).

ROTEX recommends a service and maintenance contract to ensure regular service and maintenance.

• Service and maintenance should be recorded in the maintenance record. The maintenance record is included in the scope of supply.

WARNING!

Improper service and maintenance work can be a health risk to persons and can adversely affect operation of the oil condensing boiler.• Service and maintenance work only by authorised and trained heating experts.

The service and maintenance work should be carried out by authorised and trained heating experts once a year, if possible before the heating period. This will avoid malfunctions during the heating period.

25BA ROTEX A1 BO - 10/2007


5.2 Service and maintenance tasks

5.2.1 Removing panelling (and cleaning it)

For the maintenance activities, sound insulation hood, boiler panelling and heat insulation layers must be removed.

1. Remove the sound insulation hood (see fig. 5-1).

2. Lift and remove the boiler panelling.

3. Remove the holding clamps on both upper heat insulation layers (see fig. 5-2). Remove both upper heat insulation layers.

Cleaning panelsThe sound insulation hood and the boiler panels are made of easy-to-maintain plastic. Clean them only using soft cloth and a mild water and soap cleaning solution. Aggressive cleaning agents with solvents can damage the plastic surface.

5.2.2 Checking the connections and pipes

• Check all oil and water-conducting components and connections for leakage and damage. If damaged, determine the cause and replace the damaged parts.

• Check all components of the flue system for leakage and damage. Repair damaged parts or replace them.• Check all electrical components, connections and pipes. Repair damaged parts.

WARNING!

Live parts can cause an electric shock on contact and cause fatal burns and injuries.• Before beginning maintenance work, disconnect the oil condensing boiler from the power supply

(switch of fuse, main switch) and secure against unintentional restart.

WARNING!

Danger of burning – hot surfaces.• Let the burner cool down for a reasonably long time before maintenance and service work.• Wear protective gloves.

Fig. 5-1 Remove the sound insulation hood. Fig. 5-2 Remove the holding clamps on the heat insulation layers

WARNING!

Improper work on live components can be a health and safety risk endangering human life and adversely affect the operation of the oil condensing boiler.• Damage restoration on live components of the oil condensing boiler may be carried out only by authorised

and recognised heating engineers.

26 BA ROTEX A1 BO - 10/2007


5.2.3 Check water pressure

• Check the water pressure in the heating system on the pressure gauge on the boiler control panel.

– Black pointer: Indication of the current water pressure in the heating system.– Green range: Permitted water pressure range.– Red pointer: Indication of the permitted minimum pressure.The black pointer must be in the green range. If it is to the left of the red pointer, the water pressure must be increased by topping up the system (see section 4.4.1).

5.2.4 Checking the condensate treatment unit

The condensate treatment unit cleans the draining condensation and neutralises its pH-value. The connection and drainage line of the condensate drain must be free from impurities.

Checking that the condensate treatment unit is working (pH value).Check functioning of the condensate treatment unit annually.

1. Dip the indicator strips (provided with condensate treatment unit) into the water from the neutralisation box outlet.

2. Remove the indicator strips after about 1 minute and compare the colour of the indicator strip with the accompanying colour table.

The numerical value above the colour combination corresponds to the pH value of the water.

pH value = 7±1: condensate treatment neutralised correctly.

pH value <6: condensate treatment not neutralised adequately.

When the condensate treatment is not neutralised adequately:

1. Check the combustion chamber and clean if needed (see chapter 5.2.5).

2. Dismantle and regenerate the condensate treatment unit.

CAUTION!

Escaping gases can cause breathing problems and poisoning.• The condensate treatment unit must always be connected and filled up, otherwise flue gases could escape

into the installation room.

The pH value measurement can be dispensed with if low sulphur EL heating oil is used exclusively and the responsible Water Authorities do not specify neutralisation.

A pH value <5 despite regular maintenance indicates that the neutralisation medium is spent and the filling quantity is no longer sufficient. In such a case, change the neutralisation medium ( 15 45 75).

27BA ROTEX A1 BO - 10/2007


Disassembling and draining the condensate treatment unit

1. Open the fixing belt (fig. 5-3, pos. 3).

2. Lift the stabilising plate (fig. 5-4, pos. 1) and pull out the connecting muff (fig. 5-4, pos. 2) from the condensate drain.

3. Lift up condensate treatment unit and drain through the connecting hose (fig. 5-5).

4. Place collector container under the hose connection. Pull out the flexible connecting hose from the condensate treatment unit (fig. 5-6).

5. Pull the condensate treatment unit out from under the boiler.

CAUTION!

Danger of chemical burns! The condensate treatment unit contains acid which can cause injury on skin contact.• Wear protective clothing when working on condensate treatment unit (protective goggles, rubber hand

gloves).• If your skin comes in contact with anything, wash the affected area immediately with tap water.• If the chemicals come in contact with eyes, immediately wash with tap water and consult an

ophthalmologist.

Fig. 5-3 Connections for condensate treatment unit Fig. 5-4 Condensate treatment unit – Wrapped connections1 Condensate treatment unit2 Wrapped connection on flue gas arc3 Fixing belt with snap closing4 Flexible connecting hose

2 Wrapped connection on flue gas arc5 Stabilising plate

Fig. 5-5 Draining the condensate treatment unit Fig. 5-6 Pull out connecting flexible hose

25

28 BA ROTEX A1 BO - 10/2007


Regenerate condensate treatment unit.To regenerate the condensate treatment unit, thoroughly rinse and vigourously shake up the shell limestone in it.

Requirement: The condensate treatment unit is dismantled.

Mounting the condensate treatment unit

Fill condensate treatment unit with water.The condensate treatment unit holds about 2.5 litres of water. It can be filled in several ways.

a) If there is an inspection opening in the connecting piece of the flue gas pipe, the condensate treatment unit can be filled through the flue gas pipe. For this, unscrew the inspection cover and hold a water hose in the inspection opening of the flue gas pipe. The superfluous water flows into the drainage system through the flexible hose (fig. 5-9).

b) The condensate treatment unit is filled through the boiler. For this, open the boiler body, remove the combustion chamber insert and hold a water hose in the combustion boiler (fig. 5-10).

• Rinse condensate treatment unit several times with flowing water (counter current), until clear water emerges (fig. 5-7). Fluff the condensate treatment unit several times so that the deposits will loosen up.

• If necessary, replace the neutralisation medium (shell limestone) ( 15 45 75).

Fig. 5-7 Rinse condensate treatment unit

1. Push the condensate treatment unit under the boiler.

2. Plug the flexible connecting hose to the condensate treatment unit (fig. 5-6).

3. Place connecting sleeve (see fig. 5-4, pos. 2) tight on the condensate drain bracket.

4. Rotate the stabilising plate downwards and snap into place (fig. 5-8).

5. Close and tighten fixing belt (see fig. 5-3, pos. 3). Tighten the belt so much that the wrapped connection cannot loosen itself (insert a wedge if necessary).

6. Fill condensate treatment unit with water.Fig. 5-8 Snap stabilising plate into place

Fig. 5-9 Fill condensate treatment unit through the flue gas pipe

Fig. 5-10 Fill condensate treatment unit through the boiler

29BA ROTEX A1 BO - 10/2007


5.2.5 Checking and cleaning the combustion chamber

If you detect contamination in the combustion chamber, the combustion chamber and burner must be cleaned. Severe contamination of the burner indicates a worn or contaminated oil nozzle or incorrect burner adjustment. If necessary, have the burner readjusted by a heating expert.

Opening the combustion chamber

Special tool: Combustion chamber key, fixed on the inside of the boiler panels (included in the supply).

• Disconnect the oil condensing boiler from the power supply (fuse, main switch off) and secure against unintentional restart.• Remove four Allan screws M10 (see fig. 5-11).• Tilt the combustion chamber upwards (see fig. 5-12). An air pressure spring keeps the upper half of the combustion chamber

open.

• Only in A1 BO 27i and A1 BO 35i: Remove cylindrical combustion chamber ring.• Remove combustion chamber insert with the help of the combustion chamber key (fig. 5-13 and fig. 5-14).

WARNING!

Danger of burning – hot surfaces.• Before starting work on the burners, the combustion chamber and the combustion chamber inserts, allow

them to cool down.• Wear protective gloves.

Fig. 5-11 Opening the combustion chamber Fig. 5-12 Fold the combustion chamber upwards

Fig. 5-13 Attach combustion chamber key(shown A1 BO 20i)

Fig. 5-14 Lift out the bottom combustion chamber insert (shown A1 BG 20i)

30 BA ROTEX A1 BO - 10/2007


Cleaning the combustion chamberDepending on the heating oil quality and the operating temperatures, deposits and contamination of varying intensity are formed in the A1 BO.

Requirement:The gap between the boiler half shell in the joint area is covered to prevent residues from the upper boiler half shell from falling into the gap.

Special tool: Cleaning brush, cleaning scraper (included in scope of supply).

Remove dry residue (mostly in the upper boiler half cup):• Loosen the dirt and soot on the combustion chamber ribs by using the cleaning brush and cleaning scraper.• Suction off the loosened dirt and soot by using a vacuum cleaner.

In the transition area between dry and moist combustion chamber areas (mostly in the lower boiler half cup) there is hard residue that can be removed only with wet cleaning. For this:• Loosen dirt and rust under running water spray (fig. 5-15) with cleaning brushes and scrapers.• Rinse off loosened dirt with clean water into the drain.

Always remove any existing residue with high pressure cleaner. For this:• Close combustion chamber without combustion chamber insert.• Unscrew burner including burner flange.• Clean combustion chamber through burner flange opening with high pressure cleaner (fig. 5-16).

Closing the combustion chamber• Insert the combustion chamber insert.• For oil condensing boilers A1 BO 27i and A1 BO 35i: Insert combustion chamber ring.• Close combustion chamber and tighten the 4 Allen screws M10 so that the combustion chamber is tightly sealed.• Connect up power supply (fuse, main switch engagement).• Start the burner briefly without the heat insulation covers and check for leaks.• Fit the heat insulation covers and the sound insulation hood.

5.2.6 Check burner and oil filter

Checking the burner includes visually inspecting the burner's condition as well as making flue gas measurements.

The quality of combustion and correct burner adjustment can only be checked with a flue gas analyser. ROTEX recommends that this test be carried out annually by a heating expert.

Fig. 5-15 Wet clean combustion chamber Fig. 5-16 Clean combustion chamber with high pressure cleaner

In the course of the maintenance activities, the automatic firing unit DKO 974 must also be rechecked to see whether it attains the rated life cycle: 10 years or 250,000 burner starts,

31BA ROTEX A1 BO - 10/2007

6 x Faults and malfunctions

6 Faults and malfunctions

6.1 Troubleshooting

The electronic system in the oil condensing boiler detects faults and displays them:– Through a fault code in the display, for faults detected by the boiler control.– Through the burner malfunction indicator on the boiler control panel and through a fault code on the display, for faults

detected by the DKO automatic firing unit which lead to an interlocking malfunction.– Through the STL indicator in the boiler control panel for a boiler overheating detected by the safety temperature limiter (STL)

that leads to an interlocking malfunction.

Troubleshooting• Detecting and remedying the cause of the malfunction.• Interlocking fault with fault code in the display: Unlock by briefly pressing the Manual button (Reset button ) on the

boiler control panel (see chapter 6.2).• STL malfunction: By unlocking the STL switch (see chapter 6.4).• If a fault shutdown occurs repeatedly, the heating system must be checked (e.g. flue system, fuel supply). Please consult

a heating expert in this case. • Non-interlocking malfunctions are indicated as long as there is a malfunction. Once the cause has been eliminated, the unit

continues to work normally.

6.2 Burner malfunctions

The LED in the reset button of the automatic firing units (fig. 2-4, pos. 9) indicates the processes of the burner control. In normal operating mode the LED sends a short flashing signal followed by an extended pause.LED display in the event of a malfunction:– LED burns steadily, the burner is shut off and locked.– The continuous lighting is interrupted every 10 seconds and a flash code is broadcast which gives information about the

cause of the last fault.

Tab. 6-1 Fault codes of the automatic firing units

l Short signall Long signal— Pause

Unlocking the automatic firing unit: Requirements: The cause of the malfunction is rectified, the burner is electrically connected.

• Turn on A1 BO.

• Reset by briefly pressing the Manual button on the boiler control (fig. 4-1, pos. 13).

• Reset by briefly pressing the Reset button on the boiler control (fig. 4-3, pos. 29).

WARNING!

Improper faultfinding and rectification can be a health and safety risk endangering human life and adversely affect the operation of the oil condensing boiler.• The faults should only be rectified only by authorised and trained heating experts.

Detailed information for the control, the operating mode and parameter setting and concerning the error codes can be taken from the "ROTEX Control", which is included in the scope of supply of the associated control.

� �

Flash Code Cause of the fault

l l l l l No flame signal within safety period

l l l l l External light during pre-ventilation time/pre-ignition time

l l l l l Contact release thermostat does not close within 400 s

l l l l l — l l l l l Manual fault shutdown

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32 BA ROTEX A1 BO - 10/2007


6.3 Overview of possible malfunctions

Tab. 6-2 Possible malfunctions on the A1 BO (Part 1)

1) see documentation "ROTEX control"

Malfunction Possible cause Possible solution

Heating system not functioning (main switch not illuminated, no display)

No mains voltage • Switch on boiler main switch• Turn on main switch of heating room• Check/switch on fuse house connection• Check/renew fuse boiler control panel

Heating does not warm up

Central heating standby switched off (e.g. timer is in economy phase, outside temperature too high)

• Check operating mode setting1)

• Check requirement parameter1) (e.g. timer programme)

Heating does not warm up enough

Heating characteristic too low • Increase parameter value1)

Hot water does not warm up

Storage charging standby switched off (e.g. timer is in economy phase)

• Check operating mode setting1)

• Check requirement parameter1)

Hot water does not warm up enough

Storage tank charging temperature too low • Increase hot water target temperature1)

Draw-off rate too high • Reduce the draw-off rate, limit throughput

Burner output too low • See malfunction "Burner output too low"

Burner output too low Burner setting wrong Oil nozzle wrong or dirty

• Rectification by the heating expert

Air/flue gas resistance too high

Oil filter dirty

Burner does not start Interlocking malfunction • Establish cause of malfunction and eliminate it• Unlock by briefly pressing the Manual button

Burner motor not running despite burner demand

No mains voltage on burner • Insert the 7-pin plug on the motor until it engages• Check voltage at the terminals L-N of the 7 pin plug• Check/renew fuse.

Plug connections of the control unit are loose • Rectification by the heating expert

Heater element or thermostat for preheating of the heating oil defective

Burner motor defective (bearing has seized)

Condenser defective

Oil pump has seized

Burner starting is hard Start delay due to bad ignition • Rectification by the heating expert

Loud, whistling mechanical noise

Oil pump is suctioning air • Rectification by the heating expert

Vacuum in the oil line too high

Burner motor bearing defective

Oil pump defective

No ignition Ignition electrodes short circuited • Rectification by the heating expert

Distance of ignition electrodes too large

Ignition electrodes contaminated or humid

Ignition electrodes burnt out

Insulating body cracked

Ignition transformer defective

Ignition cable burnt

Automatic firing unit faulty

33BA ROTEX A1 BO - 10/2007


Tab. 6-3 Possible malfunctions on the A1 BO (Part 2)

6.4 Rectifying STL fault

When the STL indicator (fig. 4-1, pos. 3 and fig. 4-3, pos. 3) lights up, it indicates the boiler overheating. The safety temperature limiter (STL) shuts off the system and locks it.

• Before unlocking the STL, determine the cause for the boiler overheating and rectify it (see tab. 6-3).

Unlocking the STL• Remove the sound insulation hood (see fig. 5-1).• Unscrew the cover on the STL.• Unlock STL switch with pointed object.• Screw on STL switch.• Install sound insulation hood.

Malfunction Possible cause Possible solution

Oil pump does not pump any oil

Stop valve at oil filter or in suction line closed • Open stop valve

Oil pump or coupling faulty • Rectification by the heating expert

Oil line has leakage (pump suctions air)

Filter blocked or leaking

Solenoid valve not opening

Oil atomisation not uniform – heavy soot deposit in flame tube

Oil nozzle loose, clogged or worn out • Rectification by the heating expert

Oil nozzle spraying angle is wrong

No oil flow Oil nozzle or LE diaphragm valve blocked • Rectification by the heating expert

Mixer device has thick layer of oil or heavy carbon deposits

Air supply insufficient • Check air supply line for clogging• Ambient air dependent operation: Check air supply opening

(min. 150 cm2 unlockable air supply opening)

Flue gas pipe of the LAS is leaking • Rectification by the heating expert

Burner setting wrong

Oil nozzle is wrong size

Combustion air quantity wrong

Suction line draws air (leakage)

Automatic flame guard does not actuate

Flame guard contaminated or defective • Rectification by the heating expert

Glass on light tube dirty

Flue gas temperature sensor switch off

Flue gas temperature too high • Clean the boiler

STL switch off Water throughput too low due to air inclusion • Vent system

Water flow too low due to valves closing too quickly along the entire heating network

• Use slow or time-offset closing valves, if necessary have overflow valve fitted

Pump standstill • Check mains connection and, if necessary, replace the pump

Storage tank switched off in operation without hot water storage tank

• Have the storage tank temperature sensor disconnected• Switch off storage tank charging circuit

WARNING!

Risk of burns due to hot boiler body.• Do not touch any metallic parts on the boiler.• Let the boiler cool down.• Wear protective gloves.

34 BA ROTEX A1 BO - 10/2007


6.5 Emergency operation

Note the following for emergency operation if the valve drive is faulty:• Press the unlocking button (fig. 6-1, pos. 5.2) and rotate the motor head of the valve drive (fig. 6-1, pos. 5.1) 1/4 turn to the

left and remove.

The 3-way diverter valve is set to the "Heating" position.

Note the following for the temporary manual parallel operation of the heating circuit and the hot water storage tank:• Pull the 6-pin plug out of the valve drive.• Place the diverter valve (fig. 6-1, pos. 5.3) in the mid-position. (only possible if the valve drive was previously in "Heating"

position.

In the event of a malfunction or incorrect settings of the electronic control, emergency heating operation can be maintained.

• Press the hand button on the control for approx. 5 seconds.

"Manual operation" appears on the display.

• Adjust the desired temperature with the rotary switch (setting range 5–80 °C).

In manual operation, the 3-way diverter valve is in the "Storage tank charging" position first. On reaching the maximum adjustable storage tank temperature, the 3-way diverter valve is switched to the "Heating" position.

1 Boiler flow2 Heating flow3 Storage tank flow4 3-way diverter valve

5.1 Valve drive5.2 Unlocking button of the drive lock5.3 Hand lever

Fig. 6-1 3-way diverter valve

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35BA ROTEX A1 BO - 10/2007

7 x Technical data

7 Technical data7.1 Dimensions and connection dimensions

Fig. 7-1 Dimensions of the model versions, side view

Fig. 7-2 Dimensions and connection dimensions of the model versions, rear view

36 BA ROTEX A1 BO - 10/2007

7 x Technical data

Tab. 7-1 Installation dimensions for oil condensing boiler A1 B0 in mm

Fig. 7-3 Dimensions and connection dimensions of the different set-ups

1 Boiler return flow2 Boiler flow3 KFE cock connection on the unit filling

line connection on KFE cock4 Flue gas/supply air connection5 Connection expansion vessel6 Burner7 Safety valve8 3-way diverter valve9 Hot water10 Circulation

G 1" IT (Box nut)G 1¼" ET / G 1" ITG ½" ITG ½" ETDN 80/125G ½" IT

G ½" IT (Bleeding line G ¾" IT)G 1" ETG ¾" ITG ¾" IT

11 Heat exchanger return flow12 Sensor immersion sleeve13 Heat exchanger flow14 Cold water15 Air/flue system (LAS) Connection piece16 Air supply hose17 Condensate drainage hose

A ROTEX A1 BOB Boiler frame (KU)C Sub-tank (US 150)

G ¾" ET

G ¾" ETG ¾" ITDN 80/120DN 50DN 40

A1 B0 15bio / A1 B0 20i A1 BO 27i A1 BO 35i

Dim. on the floor on US 150 on stand on the floor on US 150 on stand on the floor on US 150 on stand

a ≥ 400

b 720

c ≈137 ≈ 785 ≈ 499 ≈ 137 ≈ 785 ≈ 499 ≈ 137 ≈ 785 ≈ 499

d 230±15 880±15 590±15 230±15 880±15 590±15 230±15 880±15 590±15

e 400±15 1040±15 790±15 460±15 1100±15 850±15 460±15 1100±15 850±15

f ≥ 1340 ≥ 1890 ≥ 1650 ≥ 1470 ≥ 2020 ≥ 1770 ≥ 1590 ≥ 2140 Υ1890

g 1100 1730 1480 1220 1850 1600 1340 1970 1720

h 625

i 300

37BA ROTEX A1 BO - 10/2007

7 x Technical data

7.2 Basic data

Tab. 7-2 Basic data oil condensing boiler

Tab. 7-3 Basic data oil burner

Boiler type A1 B0 15bio A1 B0 20i A1 BO 27i A1 BO 35i

Product Identification Number (CE number) CE 0645 BM-105.2

Length 720 mm

Width 625 mm

Height 1100 mm 1100 mm 1220 mm 1340 mm

Weight of the boiler body 49 kg 49 kg 58 kg 67 kg

Transport weight Unit (without panels and condensate preparation)

81 kg 81 kg 96 kg 113 kg

Water content 3.0 l 3.0 l 4.5 l 5.0 l

Rated thermal output (according to DIN-EN 303) 12–15 kW 12–20 kW 20–27 kW 25–35 kW

Set rated thermal output upon delivery 14 kW 18 kW 25 kW 30 kW

Setting range (burner with series configuration) 14–15 kW 15–20 kW 25–27 kW 27–32 kW

Output range for burner conversion URS 12: 12–13 kW URS 12: 12–15 kW URS 20: 20–24 kW URS 25: 25–27 kWURS 35: 33–35 kW

Maximum permissible flow temperature 80 °C

Maximum permitted operating overpressure 4 bar

Boiler efficiency up to 105 %

Energy efficiency according to efficiency guidelines

CO emission class (acc. to EN 303-2) 3

NOx emission class (acc. to EN 303-2) 3

Diameter of flue gas connection/air supply connection

80/125 mm

Voltage supply 230 V~, 50 Hz


Burner type ROTEX BL 15 ROTEX BL 20 ROTEX BL 27 ROTEX BL 35

Burner output 12.4–15.5 kW 12.4–20.8 kW 20.4–27.8 kW 25.5–36.8 kW

Oil-throughput 1.05–1.32 kg/h 1.05 kWh/–1.75 h 1.72–2.34 kg/h 2.15–3.10 kg/h

Heating oil Extra light as specified in DIN 51603-1, preferably low sulphur

Maximum bio-heating oil ratioBTL or FAME acc. to DIN V 51 603-6

20 % 10 % (20 % after burner retrofit)

Hydraulic system Single stage with oil preheating

Air regulation Linearised air metering drum

Regulation ratio 1:1

Voltage supply 230 V~, 50 Hz

Electrical power consumption (pre-ventilation) 250 W (10.0 bar) 260 W (14.5 bar) 260 W (11.5 bar) 265 W (14.5 bar)

Electrical power consumption (continuous operation)

225 W (10.0 bar) 230 W (14.5 bar) 225 W (11.5 bar) 250 W (14.5 bar)

Weight 9.5 kg 9.5 kg 9.5 kg 10.5 kg

Test as specified in EN 267 Registration number: 5 G 966/2001

Output electrical motor at 2800 min−1 90 W 90 W 90 W 180 W

Protection type IP 40

38 BA ROTEX A1 BO - 10/2007

7 x Technical data

Tab. 7-4 Classification of burner components in the A1 BO

Integrated connection group

Tab. 7-5 Technical data of the integrated connection group


Burner type ROTEX BL 15 ROTEX BL 20 ROTEX BL 27 ROTEX BL 35

Automatic firing unit DKO 974 Mod. 5 (Satronic)

Flame monitor Satronic IRD 1010 red axial or BST Solutions KLC 2002 axial

Ignition transformer Beru Type MKZ 100 No. 0 096 600 017: 2x 7.5 kV, 20 kHzor Danfoss Type EBI No. 052 F0077: 2x 7.5 kV, 20 kHz

Solenoid valve Danfoss Type 071 N 0051

Oil pump, pumping capacity Danfoss Type BFP 21 L3 LE, No. 071 N2110

Oil preheating Danfoss Type FPHB-LE/PTC 70 No. 030 N4101or Danfoss Type FPHB-LE/PTC 50 No. 030 N4257

Motor ACC EB 95C 28/2, 90 W ACC EB 95C 52/2, 180 W

Boiler type A1 BO 15bio A1 BO 20i A1 BO 27i/A1 BO 35i

Heating circulation pump Grundfos ALPHA+15-40 CES Grundfos UPS 15-60 N1 CES 87 Grundfos ALPHA+15-60 N1 CES

Voltage 230 V, 50 Hz

Maximum power consumption 45 W 90 W 80 W

Protection type IP 42 IP 44 IP 42

Permitted overpressure 3 bar

Maximum pumping height 3.8 m 6.0 m 6.2 m

3-way diverter valve

Voltage 230 V, 50 Hz

Maximum power consumption 4.3 W

Protection type IP 40

Turnaround time 6 s

39BA ROTEX A1 BO - 10/2007

7 x Technical data

Remaining pumping height

Fig. 7-4 Remaining pumping height A1 BO 15bio

ΔpR Remaining pumping height mH Flow heating network

Fig. 7-5 Remaining head A1 BO 20i (stage 1 blocked)


m / L/hH

p/

mW

s�

R

I II III

0

0,5

1

1,5

2

2,5

3,5

3

4

0 200 400 600 800 1000 1200 1400 1600

min

max

min

max

0

100

200

300

400

500

600

0 200 400 600 800 1000 1200 1400 1600 1800 2000

I II III

m / L/hH

p/

mbar

�R

40 BA ROTEX A1 BO - 10/2007

7 x Technical data

Fig. 7-6 Remaining pumping height A1 BO 27i


Fig. 7-7 Remaining pumping height A1 BO 35i


m / L/hH

p/

mbar

�R

I II III

0

100

200

300

400

500

600

0 200 400 600 800 1000 1200 1400 1600 1800 2000

min

max

min

max

m / L/hH

p/

mbar

�R

min

max

0

100

200

300

400

500

600

0 200 400 600 800 1000 1200 1400 1600 1800 2000

min

max

I II III

41BA ROTEX A1 BO - 10/2007

7 x Technical data

7.3 Wiring diagram

Fig. 7-8 Wiring diagram for oil condensing boiler A1 BO (shown with ROTEX THETA 23R Control)

1 Mains switch2 Burner malfunction indicator3 STL indicator4 Manometer5 Controller: Central unit THETA 23R17 Safety temperature limiter (STL)S18 Stickers for connection diagram19 Circulation pump for heating20 3-way diverter valve21 Oil burner22 Outside temperature sensor23 Storage tank temperature sensor24 Flue gas temperature sensor

25 Return flow temperature sensor26 Flow temperature sensor 27 Switchboard PCBJ1 3-pin circuit board connector with pump cableJ2 4-pin circuit board connector with valve cableJ3 6-pin circuit board connector with clamped

burner cableJ3A Standard connector oil burner (7-pin)J3B 2-pin plug for remote burner unlockingJ4 Communication connection internal (not loaded)J5 4-pin circuit board connector with malfunction

indicator cable J6 4-pin circuit board connector with clamped

mains cable and earthing slots

J7 7-pin circuit board connector for clamping a mixer motor and a mixer circulation pump

J8 12-pin circuit board connector for clamping sensors, BUS- and control lines (storage temperature sensor and cable for external sensor are clamped)

J9 5-pin circuit board connector with STL cableJ10 8-pin circuit board connector with flue gas,

flow and return flow sensor cableJ14 3-pin circuit board connector for clamping

a circulation pumpJ15 4-pin circuit board connector with switch cable

42 BA ROTEX A1 BO - 10/2007

8 x Glossary

8 Glossary

Additional water The volume which needs to be added to compensate for water losses.

Air/flue system (LAS) System comprising the flue gas and air intake pipes which cools the flue gas and heats the intake air in a counterflow principle. On the one hand the heat of condensation from the flue gas is used. On the other hand the flue gas heats up the combustion air that is drawn in. Both factors increase the efficacy of the installation.

Ambient air dependent operation

Operating mode of the installation whereby the boiler draws the air required for combustion from the installation room.

Automatic firing unit The system that starts and controls the oil burner, that monitors the combustion process and switches the oil burner off in the event of a malfunction.

Boiler control panel Operating panel on the front area of the boiler which contains the main switch, the warning lamps, the water pressure gauge and the programme selection buttons, the rotary switches and the display.

Burner setting Settings on the oil burner which can only be carried out by engineers, for example setting the oil-air mixture,the burner output and the electrodes.

Calorific value Energy created by combustion of the fuel and from condensation of the flue gas which is produced as heat and which can be used (synonym = gross calorific value)

Condensate preparation unit

Unit for cleaning and neutralising the condensation product created when the combustion gases cool down (strongly acidic).

Condensing technology

Heating technology which uses, in addition to the sensitive combustion energy (calorific value), the heat of condensation of the flue gas, thus increasing the efficiency of the system.

Control Electronic operating and control unit for controlling the burner, valve and pump, with which the thermal conditions of the heating system are determined and monitored.

Control measurement An analysis of the flue gas is carried out at a defined operating condition of the boiler in order to monitor the quality of combustion. There is an automatic programme integrated in the control for this purpose.

Energy saving directive (ENEV)

Legal directive which defines the standards of construction and heating technology and which evaluates the efficiency of the heating and hot water preparation system.

Filling water Volume of water which must be poured into the heating system before initial start-up.

Flue gas mass flow Volume of flue gas produced during combustion and directed to the open air via the flue system, depending upon the set burner output.

Heat of condensation Energy created by the condensation of the water vapour in the cooling flue gas and which is used to generate heat in condensation technology.

Heating characteristic curve

Mathematical relationship between the external temperature and the target flow temperature (synonym = heating curve), in order to achieve the desired room temperature at all outside temperatures.

Heating circuit Circuit of heated water from the boiler to the radiators and back.

Heating return Part of the heating circuit that directs the cooled water from the radiators in the rooms back to the boiler via the piping system.

Heating return flow Part of the heating circuit that directs the heated water from the boiler to the radiators in the rooms.

Nominal output Maximum heating output which the boiler produces at specific operating temperatures.

Operation independent of ambient air

Operating mode of the installation where the boiler does not draw the air required for combustion from the installation room, but from outside via the air-flue gas system. ROTEX recommends this method of operation.

Timer programme Time settings that are entered in the control to specify regular heating, setback and hot water phases.

Water shortage/overheating protection

Safety device which switches the boiler off automatically in the event of a water shortage to prevent overheating.

43BA ROTEX A1 BO - 10/2007

For the chimney sweep9

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8 For the chimney sweepData for designing the flue gas pipe

Tab. 8-1 Triple values for chimney design

Unit type Boiler rated output in kW

Flue gas mass flow (humid) in g/s Flue gas temperature in °C Available delivery pressure in Paat 75/60 °C at 40/30 °C 75/60 °C 40/30 °C

A1 BO 15bio12 5.32 5.17 70 48 15015 6.72 6.49 75 52 150

A1 BO 20i12 5.32 5.17 70 48 15015 6.72 6.49 75 52 15020 9.03 8.67 85 65 150

A1 BO 27i20 9.03 8.55 79 53 10023 10.49 9.86 84 61 10027 12.40 11.61 89 68 80

A1 BO 35i25 11.29 10.69 84 58 10030 13.68 12.86 95 66 10035 16.08 15.05 98 74 80

Control measurement

The check measurement can be carried out by an easily selectable automatic function (see also the supplied "Quick reference instruction manual" or the "Instruction manual for ROTEX-Control").

Control ROTEX THETA 23R

1. Press Manual button (fig. 4-1, pos. 13).

The oil condensing boiler controls the maximum boiler temperature for a period of 20 minutes.

2. Press Manual button again within this period.

End emission measurement prematurely, return to the previous active operating mode.

Control ROTEX ALPHA 23R

1. Set the "default settings" rotary switch (fig. 4-3, pos. 6) to position .

2. Simultaneously press the and buttons (fig. 4-3, pos. 8 and 9).

The oil condensing boiler controls the maximum boiler temperature for a period of 20 minutes.

3. Press the and buttons within this period.

End emission measurement prematurely, return to the previous active operating mode.

Remaining time from activation

Current heat generator temperature

End emission measurement prematurely

Fig. 9-1 Brief instructions for chimney sweep operating mode in symbols ROTEX THETA 23R

Fig. 9-2 Brief instructions for chimney sweep operating mode in symbols ROTEX ALPHA 23R

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mET Flue gas mass flowP Burner output

Fig. 9-3 Flue gas mass flow in relation to the burner output

44 BA ROTEX A1 BO - 10/2007

ROTEX A1 BO - professional.rotex-heating.com · The oil condensing boiler ROTEX A1 BO xxi may be...

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